Prefabricated structure



March 19, 1940. w. F. WEAVER 2,193,994

PREFABRIGATED STRUCTURE Filed June 1, 19:57 2 sheets-sheet 1 March 19, 1940. w. F; WEAVER 2,193,994

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v M attomeg Patented Mar. 19, 1940 UNiTED STATES PATENT OFFICE PREFABRICATED STRUCTURE Walter F. Weaver, Los Angeles, Calif.

Application June 1, 1937, Serial No. 145,690

10 Claims.

My invention has reference to prefabricated structures, and has for its chief purpose to provide a plurality of sheet steel units, of the same general character, which can be formed in a factory, and assembled at the place where they are to be used, with a minimum expenditure of time and labor. The various panels or sections are provided with means for being detachably united, so that other sections can be added to those already in place. When the sections are united they form a rigid, and integral structure, embracingthe complete body portion of a floor, or of a side wall, or end wall, or roof, or Whatever part of a building they may be designed for. The invention has for its purpose to provide for the construction of houses of relatively low cost,

which can be utilized for company houses and stores, settlement houses, summer cottages, and other buildings. The great reduction in the cost oi!v such structures is due partly to the substitution of sheet steel for the more costly materials of wood and concrete, and partly to the possibilities ofmass production, along the linel of regular pattern construction, and with the parts all ready for completion of the buildings in short order. Another advantage of the use of the sheet steel is the facility with which the same may be made to conform to patterns of construc tion, such as the outer walls which can be formed to imitate brick or stone, and the' roof plates,

which can be made .to simulate shingles or tile.

In its simplest form the various sections include supports of a novel character, produced by bending a piece of sheet steel into a desired shape, with adjoining edges provided with means for engagement with the edges of a plurality of sheets of the metal, which unite said supports, and form one of the panels or sections. In the wall sections these supports form the studding, in the ioor and ceiling they constitute the joists, and in the roof sections, the rafters. The wall sections can be formed complete, with openings for windows, doors, and the like, between adjacent studding, and with windows and doors in place, ready for use, when they leave the factory. The sections can also be provided with openings for plumbing connections, and connections for electric wiring, before they are put in place. All work of that character, as well as interior and exterior painting and decorating, can also be taken care of before the parts are assembled.

Another feature of the invention consists of a system of insulation between various of the metal parts, serving as a thermostatic control, and adding to the durability of the structure. f

Another purpose of the invention is to provide a means for quickly uniting the various sections, not only in the different' panels, but for connecting one panel or section with another, as a wall section to a roof section, or to a iioor section, and 5 the like. This means is also of such a character as to permit the parts to be quicklyseparated, if desired, and as quickly put together again.

Another feature of the invention consists of a iluted floor construction, with channels permit'- 10 ting the circulation of air therethrough, with an arrangement which will permit of the entrance of heated air to the rooms in cooler weather, or conversion thereof into an air cooling system u nder summer conditions.

Being formed of sheet metal throughout, the sections are of comparatively light weight, and can easily be handled in sections of considerable size. While the invention is set forth herein in its adaptability to the construction of homes of 20 the smaller type, it is not limited thereto, but can be readily applied to the building of garages, barns, stores, and similar structures.

The various sections are formed of two spaced wails, the spaces in which can be utilized for in- 25 sulating material, forming a non-conductor for sound, heat, or cold.

The above-named, and other features and advantages of the invention will more fully appear from the following specification, reference being 30 had to the accompanying drawings, in which:

Fig. l is a perspective view of one of the supporting members, partly broken away.'

Fig. 2 is a horizontal section of a structure embodying the invention.

Fig. 3 is a vertical `sectional view of a joint in ceiling construction.

Fig. 4 is a vertical section of a fragmentary wall and roof construction, with parts broken away.

Fig. 5 is a similar view of roof construction, at the ridge thereof.

Fig. 6 is a fragmentary portion of a section of flooring, with parts of the floor broken away.

Fig. 7 is a cross-section, .on the broken line 45 1--1 of Fig. 6.

Fig. 8 is a detail of one of the members I0, en-

larged.

Fig. 9 is a cross-section on the line 9-9 of Fig.

6, with a section of wall construction at one side 50 thereof.

The reference number I0 indicates aV support of triangular form, shaped from a single sheet of steel, one of the edges thereof being provided with a series of hook-shaped lugs I2, and the opposite 5s edge of said sheet is provided with similar lugs I3, oppositely disposed to the lugs I2, and alternating in position with said lugs in spaces I4 therein. 'I'he members I0 are formed from a fIat piece or blank of the metal, the edges being flrst cut to form the lugs, and the sheet then bent into the desired form. As shown in Fig. 2 of the drawings the supports are disposed at regular intervals in the wall, to form the studding thereof. 'I'hey may be made of any desired length, and width, but would usually be ofthe length of the studding or other parts which they replace. They can also be disposed in a horizontal direction, to supply the joists of a floor or ceiling, or in a sloping position in a roof, forming the rafters thereof.

Uniting the supports I0 are sheets I5, provided on their edges with curved flanges I6, those on one edge of a sheet engaging the lugs I2, and those on the other edge engaging the lugs I3. When in this position the sheets I5 are designed to form the inner wall of a structure, and in some cases the outer wall. The sheets I5 are placed so that the flanges I6 are adjacent and parallel to each other, and the lugs I2 and I3 of the supports I0 are in complete engagement therewith, as shown in Fig. 2, and forming a complete wall or other section.

Spreaders I1, also formed of sheet steel, are inserted in the members I0, tending to force the rows of lugs I2 and I3 toward each other, and hold the sheets securely in position. The sheets of steel are of standard width, approximately 16 inches, and are used in multiples thereof, thereby forming one of the sections of a building, for example, a wall, a partition, a floor, or a ceiling or roof section. If it is desired to remove a building, or make changes therein, the spreaders I1 are removed, and the plates I5 slipped from place. The parts can be again replaced in the manner before described.

Sheets I8 of steel are secured to the bases II of the supports I0 by spot-welding or mechanical methods, said sheets being in parallel relation with the sheets I5, and forming the outer or inner Wall of the sections. Said sheets may be given the appearance ofv wall structure, or veneer, or other plates can be attached thereto, as shown at I5A in Fig. 4 and Fig. 8. In the first case an extra roof plate is secured to the plate I5, having the appearance of shingles or roofing, and in Fig. 8 an extra plate is shown secured to the sheets I5, by means of welding or other suitable means. With the parts in a proper position the plate I5A shown in Fig. 8 could be used for the outside wall, and made to represent any kind of siding desired. This could be in the form of stone, brick, etc. as before mentioned. In some cases the positions of the sheets forming the walls will be reversed, with the sheets I5 on the outside. The walls can not only be given the desired configuration, but they can be painted or decorated, or given such nish as may be desired, before being shipped for use. l

In Fig. 2 is shown a portion of a structure in which the walls form an angle, and wherein the sections are united by anchor-plates 20 and 2|. The plate 20 is of fluted formation, so as to form alternating ribs 22 and channels 23, and the plate '2l is similarly formed into ribs 24 and channels 25, which are in interlocked engagement with the rst-named'ribs and channels. When in such interlocked position the fluted parts are held together by means of pins 26, passing through perforations in said parts. The anchorplates are rigidly attached to the sections, as by welding, so that the anchor-plates are movable with the building sections. The anchor-plates just described also serve the purpose of a corner studding, and no other support is needed at'that point.

In Fig. 3 is shown a section of ceiling construction, in which the ends of two joists III and IIIa come together, with a partition wall just below the joint. On the upper edge of the partition wall is an anchor-plate 3|, having a fluted portion in which is supported a pair of short fluted members secured to the ceiling walls I3. Said fluted parts are held together by pins as before de-.J scribed, and if it is desired to disconnect said parts the pins are withdrawn, and either of the plates 32 lifted from its place. This shows the idea adapted to a right-angle connection of walls.

The anchor-plates are used generally for properly aligning all of the building sections, and

locking them together. With the exception of the floor section the edges are completely provided with the anchor-plates, which form portions of the studding and other supports, and which can be readily adapted for use in corners, on roofs. in valleys, hips, on gables, ridges, and any other part of the construction of a building. The flexibility of the anchor-plates is such that they can be utilized in locking the sections together in any and all angle formations.

Fig. 4 shows part of a floor section and side wall, with the fractional part of a roof rafter connecting with the side wall. The floor plates are connected with the side walls by means of anchor oor plates 33 and 34, united by pins 35.

`The roof sections and upper ends of the side walls are similarly connected by means of plates 38 and 31, interlocking and secured together by pins 38.

In Fig. 5 is shown a joint at the ridge of a roof, wherein the roof sections are united by anchor ridge plates 39 and 40, united by pins 4 I.

Anchor-plates of the type set forth herein also form guides in positioning the various sections, and are self-seating and self-aligning. By the use of said interlocking members a rigid construction is secured, and one that possesses a high degree of architectural flexibility.

The supporting members I0 are of a light but strong construction, and they also provide a Ventilating means for the structure in which they are placed. If desired, the space between the inner and outer walls can be filled with insulating material, of a character which will not readily conduct heat, cold, or sound.

In Fig. 8 the engaging parts of the plates I5 and supports I0 are shown separated by an insulating sheet 42, forming a non-conductor between said parts, and aiding in preventing differences in temperature on the inside and outside of a building conflicting through said metal parts.

In some structures the floor sections can be of the same general construction as the side walls, or the reverse, but in Figures 6 and 7 of the drawings is shown a special floor construction, embodying a fluted sheet 44, having alternate upper and lower spaces 45 and 46. The upper spaces are in the form of troughs, and are filled with a foundation material, 41, upon which is laid a flooring 48, which may be of linoleum, tile, or other material. The sheets 44 are in sections, and are supported by-a number of the members Il, extending transversely thereof. Two of said sections are locked together by means of one of said supporting members, as shown at the right in Fig.

9, wherein the lugs on the upper part of the support are in engagement with anges on the edges of metal sheets 49, securedto the lower side of the sheet 44, as by spot welding. Central supports of a modiied type may be provided, consisting of triangular joists 50, provided with angularly disposed lianges 5|, to which is attached a metal strip 52, by Welding or other fastening means, and the strips 52 are in turn secured to the uted sheet 44. The supports 50 are thereby' permanently attached to the floor sections, and can be moved therewith.

The spaces between the sheets 49 and 52 are closed by strips 59 of asbestos or other nonconducting material, whereby the spaces 46 are formed into ducts or ues for the circulation. of air therethrough.

At the left in Fig. 9 is shown a section of wall of the standard construction, provided with the studding I0, and having spaces formed at 53 in rear of a'base-board 54, by means of haine-plates 55 inserted between adjacent supports I0. Openings 55 extend through the wall I5 and baseboard, and similar openings 51 connect said spaces with the endsof the channels 46, formed in the upper face of the sheet 44. A portion of the outer wall of the building extends downwardly and is attached to a mud-sill 58, upon which the supports Il! and 50 rest. The part below the iioor is enclosed by said wall extension, and by closing the ends of some of the channels 46, others of said channels will serve as conduits, for conveyance of air to the spaces 53, and then into a room through the openings in the baseboard. The source of heat is not shown herein, but may consist of any suitable heating element, such as a nre-place in one end of the building, and connections from the same with the heat channels. An electric blower can also be provided at the source of heat supply, for stimulating the circulation of air in the system. Spaces similar to those shown at 53 can be provided in the upper part oi.' the walls, and made use of with the channel system for an air cooling effect in hot weather. In this use the current of air through the system would be reversed.

The wall shown in Fig. 9 has the appearance of being a side-wall, but partition walls 'can be similarly formed; with openings from the space 53 into rooms at each side thereof.

,when claim, and desire to secure ministers.l

Patent, is:

1. A structural device, comprising a support of sheet steel oftriangular cross-section, provided along one of its angles with oppositely hooked intermeshing members, and wall sheets provided with flanged edges engageable with said intermeshing members.

2. A structural device, comprising a support of sheet metal of triangular cross-section, open along one of its angles, and provided adjacent said opening with alternating oppositely disposed tlanges forming teeth, and wall sheets engageable at their edges with said toothed anges.

.3. A structural device, comprising a support of triangular sheet metal formation, open along one of its angles, and ,provided along said opening with oppositely and alternately disposed pairs of engaging. lugs, wall sheets provided with ilanged edges for engagement with said lugs, and a spreader insertable in said support to lock said sheets tromrelease.

4. In a structural device, a plurality of sheet metal `supports of triangular cross-section, lhaving a joint along one of its angles and alternating oppositely disposed pairs of lugs along the edges. of said joint, wall sheets provided along their edges with means for engagement with said lugs, and wall sheets attached to the opposite sides of said supports in parallel relation with said rst-named sheets.

5. A structural device, comprising a series of supports of sheet steel formation, and triangular in cross-section, having .joints at one of each of their angles, oppositely disposed intermeshing hook members along the Aedges ofsaid joints, wall sheets provided with hook flanges for engagement with said hook members,- and secondary wall sheets attached to the opposite sides of said supports in parallel relation with said first-named sheets.

6. The combination of a series of supports of sheet steel formation, two series of engaging lugs of lugs toward each other to prevent release of said sheets.

7. In building construction, a suitably supported floor including a uted sheet steel plate,

metal studding supported on said oor, a sheet steel anchor plate secured to the ends of said studding, of fluted formation coincidingwith that of said oor-plate, and interlocking therewith, means for holding said anchor-plates and iioor plate from separation, sheet steel walls sup-v ported from said studding in spaced parallel relation, and a iioor filler for the upper face of said hoor-plate, on the outside of the walls.

8. In buildingconstruction, a iioor including a uted sheet steelplate, triangular sheet steel joists supporting said plate, hollow sheet-steel studding supported on said oor-plate, and provided at their lower ends with iluted plates interlocking ygith the flutes of said door-plates, fasteners passing through the iiutes of said floorplates and said studding plates, sheet-steel walls formed in sections of uniform size attached to said studding, iluted anchor-plates uniting said sections and held in interlocking position, and a iiller for said iioor plate, forming a iioor thereon, between the walls.

9. A structural device, comprising a plurality of wall sheets formed into engaging means at their opposite edges,V a plurality of sheet metal including pairs of flanged plates at the joints of said sections, triangular supports for said pairs of plates provided with intermeshing toothed members for engagement with said flanged plates, and auxiliary triangular supports for the others of said cross-plates.

. WALTER F. WEAVER. 

